101608-6540 ZEXEL 9 400 619 604 BOSCH INJECTION-PUMP ASSEMBLY 9400619604 1016086540

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 604 9400619604

ZEXEL 101608-6540 1016086540

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Buy INJECTION-PUMP ASSEMBLY 101608-6540 zexel genuine, new aftermarket engine parts with delivery

Service parts 101608-6540 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9290

3. GOVERNOR 105401-1430

4. SUPPLY PUMP 105220-7110

5. AUTOM. ADVANCE MECHANIS 105676-1320

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6920

11. Nozzle and Holder ME440837

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE

105017-3120

15. NOZZLE SET

Include in #1:

101608-6540 as INJECTION-PUMP ASSEMBLY

101685-0550 as _

Cross reference number

BOSCH 9 400 619 604 9400619604

ZEXEL 101608-6540 1016086540

Zexel num

Bosch num

Firm num

Name

101608-6540
101608-6541

9 400 619 604

INJECTION-PUMP ASSEMBLY
* K 14BE PE6A PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-5520

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.5 3.45 3.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 8.3

Pump speed r/min 1025 1025 1025

Average injection quantity mm3/st. 84 83 85

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 56 56

Boost pressure mmHg 420 420

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 8.5 7.2 9.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position 8.5++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 65 70

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-0.7

Boost pressure kPa 30.7 24 37.4

Boost pressure mmHg 230 180 280

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(8.3)

Boost pressure kPa 46.7 44 49.4

Boost pressure mmHg 350 330 370

Timer adjustment

Pump speed r/min 0

Advance angle deg. 3 2 3

Load 0/4

Timer adjustment_02

Pump speed r/min 650+-25

Advance angle deg. 3 2 3

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min 750+-25

Advance angle deg. 0 0 0

Load 0/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Torque control stroke: L1 (5)Rack difference between N = N1 and N = N2 (6)Set idle sub-spring (7)Main spring setting (8)Boost compensator stroke: BCL
----------
K=12 L1=0.3+-0.1mm N1=800r/min N2=300r/min BCL=0.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Base lever only
----------

----------
a=3deg+-5deg b=18deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position = aa, speed = bb (stamp at delivery) (3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=25mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(130deg)

Information:

Water Pump
Disassembly of Water Pump
Inspection of Water Pump
If the inspection of the impeller and shaft finds abnormal noise or rough rotation, replace the assembly.
Inspection of impeller and shaft rotation conditionThermostat
Disassembly of Thermostat
Inspection of Thermostat
To test the thermostat operation, immerse the thermostat in a container filled with water, and heat the water while measuring the water temperature. Record the temperature at which the valve starts to open and the temperature at which the valve lift becomes 8 mm [0.3 in.] or more. (a) Stir the water in the container to ensure uniform temperature distribution.(b) When installing the thermostat, be sure to check the valve opening temperature indication stamped on the upper face of the thermostat mounting flange.
Inspection of thermostatThermo Switch
Inspection of Thermo Switch
Immerse the temperature sensor in oil, and measure the resistance while increasing the oil temperature. If the temperature measurement exceeds the standard value significantly, replace the thermo switch.
Since the inspection requires heating of oil to high temperatures, be careful not to get burns or start a fire.
Inspection of thermo switch